Document KzaX6w2okNgpXVpyw9mdg0Rzx

SPECIALTY CHEMICALS DIVISION SOUTH CHARLESTON PLANT ENGINEERING May 28, 1987 receive0 TO: 1) W. D. Bradbury, Jr. 2000-4335 v^7 a rs HOL-L " '** 2) M. G. Dwyer L3489 CC: J. R. Dement G. R. Hattiangadi G. F. Hayes Ris^*Hul3^Jr.'* R. G. Link/B. N. GUatta A. Lynch SUBJECT: 930-WORK ORDER REQUEST 514-0586 ASBESTOS INSULATION UPGRADE - PHASE I SPECIALTY CHEMICALS DIVISION SOUTH CHARLESTON PLANT The attached Work Order Request has been approved by local management. Please obtain additional approval signatures and process through regular channels. wdm Attachment 3405G UCC 006569 SPECIALTY CHEMICALS DIVISION ENGINEERING DEPARTMENT CAPITAL WORK ORDER 330- JOB NUMBER NP-8009 PACE 1 OF 8 TITLE: ASBESTOS INSULATION UPGRADE - PHASE I SOUTH CHARLESTON PLANT See opr.opt.sys. 326100 profit center Attached LOCATION 514; BLDC.NO. REQUEST OR JOB NO.i 514- 0586 SPONSOR Specialty Chemicals Div depTi Maintenance projecti jFDodd BUDGET NUMBER ENDORSEMENT / APPROVAL ROUTING: PROJECT PRIORITY B,C,D, ADMINISTERED BY: ( )PLANT(AD.CODE 2) K 1464 (AD.CODE 1) ( )DISTRIBUTIONtAD.CODE 3) TITLE t24 SPACES) Asbes Insul Upgrd Phi ACCOUNT ORDER NO. DATE UIKHEZmO' 9)310101010 111I------------0- ,8, 1,8,7 $9o0,ooo The justification of this project is Occupational Health. The asbestos insulation throughout the Plant must be upgraded to comply with Occupational Safety and Health Administration (OSHA) Standards. The long-term plan is to remove asbestos from idle equipment, replace damaged asbestos insulation with an approved type, and seal all remaining asbestos insulation. This project is Phase 1 of the program for work to be completed in 1987 on that asbestos insulation with the highest exposure potential to employees. PRINCIPLE TYPE OF project Occupation Health )NPV H NA AUDIT REQ. YES03 NOQ DATE 4088 CAPITAL COST tRANGE* 10 X CR ISSUE NA UJLKL bNUWSbKNT ENVIRONMENTAL OCC. HEALTH SAFETY ENERGY ENERGY CONSERVA. JLW ~H3S MJS TGS TGS INCLUDES: AIR POLLUTION CONTROL ----------------- NO mftEP 1 irrjpw rnwrpni X RESIDUE(SOLIDS)DISPOSAL X OCC. HEALTH $900,000 X SAFETY X NOISE CONTROL X TOTAL H,S. 4 EA $900,000 NA RETIREMENT OF PROPERTY (1) 838000 liil $900,000 270,000 EXPENSE (REARRANGEMENTS. REVISIONS. ETC.) CAPITAL EXCLUSION TO PROFIT CENTER EST .CONSTR.COMP.DATE 4Q87 DISTRIBUTION OF APPROVED HORK ORDERi W. D. BRADBURY, JR. 0. R. DEMENT B. N. GLIATTA J. F. DODD A. WALKER G. F. HAYES M. G. DWYER A. B. WILLIAMSON 6. R. HATTIANGADI J. E. McKEON D. G. M0SHIER R- G- HULL W0RSTELL M. J. SH0GER R. G. LINK M. D. FAIRALL G. M. R0SENGARTEN,JR(2) A. LYNCH (2) 838000 1 L1 t DATE TOTAL ESTIMATE $1,170,000 ---4-................A..P.P..R.OVALS .......... f/zCAl s/zr/^7 (Jtt/Uta.. J WJf 1 /1 cost summary TO: JF Dodd 82-712 <514)(2) CAD421 10/11/85 UCC 006570 Page 2 of 8 OBJECTIVE The objective of this project is to minimize hazards of airborne asbestos in the South Charleston Plant. The potential highest exposure areas throughout the Plant will be brought into compliance with Occupational Safety and Health Administration (OSHA) Standards. JUSTIFICATION The justification of this project is Occupational Health. The asbestos insulation throughout the South Charleston Plant must be upgraded to comply with the OSHA Standards. The long-term plan is to remove asbestos from idle equipment, replace damaged asbestos insulation with an approved type, and seal all remaining asbestos insulation. Based on the recently enacted OSHA Standards, the overall plant program will cost about $8,000,000 to $10,000,000 over the next several years. This project is Phase 1 of the program for work to be completed in 1987 on that asbestos insulation with the highest exposure potential to employees; the cost of the Phase 1 project is $900,000 capital and $270,000 expense. The remaining work on the overall Plant program is planned for execution over the next four years at about a $2,000,000 a year expenditure. The recently enacted OSHA Standard 29 CFR 1926.58 has.significantly increased the cost of removing and repairing asbestos insulation due to increased job preparation, execution, and cleanup requirements. Negative pressure enclosures are required "where feasible" for large scale removal, demolition and renovation operations. FACILITIES REVISIONS Asbestos removal/upgrading will take place throughout the Plant. The project will focus on correcting the worst case potential exposure in each unit of the Plant and the preliminary dollar-value of work in each area is shown in Table 1 on page 7. ENVIRONMENTAL PROTECTION/OCCUPATIONAL HEALTH AND SAFETY CONSIDERATIONS This project will correct an Occupational Health concern by replacing or sealing exposed asbestos insulation that has the highest exposure potential throughout the Plant. When the insulation is being replaced or removed, Safety and Health Guidelines will be followed which includes: installing barricades and clearing the area of plant personnel, posting of warning signs, proper bagging and disposal of insulation, and monitoring of surrounding work areas. In addition, assuring that personnel adhere to guidelines such as: wet clean-up, wearing of appropriate respirators, wearing and disposal of proper protective clothing, construction of negative pressure enclosures, etc. UCC 006571 Page 3 of 8 Project execution will be in compliance with all applicable OSHA and EPA Regulations. The EPA will be notified that the removal of asbestos insulation could occur at the South Charleston Plant. A designated, trained "competent person" will oversee the removal/repair activities. The required Health, Safety, and Environmental review of the overall plantwide replacement or sealing of asbestos insulation was completed on October 30, 1986, for a proposed Outline of Project (0/P) by the Engineering, Manufacturing, and Technology Services Department (EM&TS). The initial phase of the work will now be executed on a working budget project and the review was updated on May 19, 1987 by EM&TS. This project is endorsed contingent upon the following: 1. Maintenance Procedure XVIII Provisions for Asbestos Material Removal and Disposal Safety will be revised to be in compliance with the latest OSHA Standard 29 CFR Parts 1910.1001 and 1926.58. 2. Procedure XVIII will be revised in accordance with the environmental concerns listed in the review. This procedure has been issued for final review. The conplete 0/P review and the subsequent review along with endorsement letters from Messrs. R. R. Rankin and D. B. Marsh are attached. This project has been endorsed by the Plant Environmental Protection Department Head, J. L. Worstell, and the Plant Safety Department Head, M. J. Shoger. EFFECT ON SUPPORTING FACILITIES The project will have no effect on support requirements. However, Energy Conservation will be improved with this insulation upgrade. PROJECT PLAN The project will be supervised by the Maintenance Department. Insulation specification consultation will be supplied by Engineering. Field construction will be provided by an outside contractor. Project Management, including cost control and reporting, will be provided by Plant Engineering. The work associated with this project will be performed by outside contractors. Powerhouse Equipment Company, an outside insulation contractor, will perform the work. Work priorities and schedules will be developed based on the criteria contained in the following "Asbestos Project Criteria". UCC 006572 Page 4 of 8 1. Analytical tests are used to identify the composition of insulation materials. 2. Work priorities and schedules are developed based upon: o verification of the insulation as asbestos o degree of deterioration of the insulation o interior locations with greater exposure potential are given priority over exterior locations with low exposure potential o scheduled or pending shutdowns are considered o potential for interference with other work activities, i.e. paint program o efficient utilization of the contractor resources (minimize skipping around) 3. All insulation material identified or applied under this program is clearly labeled for future reference. 4. Records are maintained documenting removal and repair activities, quantities of asbestos insulation removed, and associated costs. 5. All applicable Federal and State regulations are followed. 6. A schedule is developed projecting 30-day work activity and is updated every two weeks. The Goff Mountain landfill will be used for disposal of the asbestos insulation. The cost of disposal is included in the project cost. The Project Team organization follows: Maintenance Department Head Maintenance Coordinator/Supervisor Project Manager (Cost Control) R. G. Hill H. Price J. R. Maier SCHEDULE All work will be completed in 1987. UCC 006573 Page 5 of 8 COST ESTIMATE The estimate for the project is based on doing $1,170,000 of work in 1987 throughout the Plant (see Table 1 on page 7): Capital 838 Expense o Labor o Materials o Engineering/Maintenance* Total $ 570,000 270,000 60,000 $ 900,000 $ 220,000 30.000 20.000 $ 270,000 * Insulation specification consultation, project management and field coordinator of contractor. COST ALLOCATIONS TO DIVISIONS The project costs are allocated to the tenant divisions as follows: Division Percent Costs Capital Expense Specialty Chemicals Solvents & Coatings Industrial Chemicals 74.4 22.1 3.5 $669,600 198,900 31,500 $200,900 59,700 9,400 Total 100.0 $900,000 $270,000 A Division Profit Center Breakdown is shown in Table 2 on page 8. JFD 05/22/87 3346G UCC 006574 Page 6 of 8 BASIS FOR AUDIT REVIEW I. PROJECT TITLE Asbestos Insulation Removal/Upgrade South Charleston Plant II. AUDIT CRITERIA TO BE USED IN REVIEW Date of Mechanical Ccxrpletion Capital Costs Non-capital Costs Estimated 4Q87 $900,000 $270,000 Actual Specific Performance Asbestos insulation exposure will be corrected in the highest exposure potential areas throughout the Plant. UCC 006575 001 004 0072^ 0072 0072) 019 04911 064 077 082 083 106 113 115 121 169 222 224 226 227 228 300 326 342 355 391 Page 7 of 8 TABLE I ASBESTOS REMOVAL/UPGRAPE PROJECT PRELIMINARY WORK BREAKDOWN AREA Water Treating Bldg. 102 Powerhouse 600# Steam Distribution Headers 200# Steam Distribution Headers 30# Steam Distribution Headers Raw Material Pipeline Chemical Mix Mpper Island Mainland Chemicals PVA Solvent Vinyl Resins Polyols Specialty Catalyst Specialty Chemicals Middle Island Oxide Adducts Drumming @ 303 Automated Warehouse Tank Truck Load/Unload Tank Car Loading/Unload/Cleaning NC Bulk Terminal Buildings Maintenance Facilities Stores Facilities Plant Laboratory Fire Station TOTALS Capital 5.0 40.0 15.0 15.0 15.0 5.0 57.5 57.5 57.5 57.0 57.5 57.5 57.0 57.0 57.0 57.5 57.0 10.0 35.0 22.5 22.5 20.0 30.0 3.0 22.0 10.0 900.0 Expense 3.0 20.0 3.0 3.0 1.0 18^0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 3.0 8.0 8.0 8.0 2.0 8.0 1.0 3.0 1.0 270.0 UCC 006576 Page 8 of 8 TABLE 2 ASBESTOS REMOVflL/UPGRADE PROJECT DIVISION/PROFIT CENTER ALLOCATION BREAKDOWN DIVISION Industrial Chemicals PROFIT CENTER 156 170 174 Sub-Total ALLOCATION % 0.3 1.8 1.4 3.5 Solvents & Coatings Materials Specialty Chemicals G. F. Hayes 3346G 163 181 188 270 271 307 311 313 314 315 316 324 326 331 332 333 381 485 Sub-Total 139 143 147 162 165 175 184 351 353 384 Sub-Total TOTAL 1.4 0.7 0.3 0.3 0.6 0.3 0.3 0.3 2.0 0.7 0.2 1.4 0.6 0.3 0.4 0.5 9.7 2.1 22.1 11.6 2.5 5.6 15.3 2.6 4.3 4.5 7.8 12.8 7.4 74.4 100.0 UCC 006577